Light-emitting module and luminaire

Abstract

According to one embodiment, a light-emitting module includes a substrate, a light-emitting element, a light distribution control member, and a cover. The substrate includes a surface on which a thermally conductive portion and a interconnect pattern are formed. The light-emitting element is thermally connected to the thermally conductive portion, is electrically connected to the interconnect pattern, and generates heat while emitting light. The light distribution control member is thermally connected to the thermally conductive portion at a periphery of the light-emitting element, includes a ridge portion formed on an exit side where light emitted from the light-emitting element is projected, and is configured to control distribution of the light emitted from the light-emitting element. The cover is thermally connected to the ridge portion and configured to pass therethrough the light emitted from the light-emitting element.

What is claimed is: 
     
       1. A light-emitting module comprising:
 a substrate including a thermally conductive portion and an interconnect pattern which are formed on a flat surface in the same plane; 
 at least one light-emitting element thermally connected to the thermally conductive portion by solder, electrically connected to the interconnect pattern, and configured to generate heat while emitting light; 
 a light distribution control member formed separately from the substrate, the light distribution control member comprising at least one cup corresponding to each of the at least one light-emitting elements, each of the at least one cup comprising a concave portion having a curved surface; a peripheral edge portion located on an incident side with respect to the at least one light-emitting element and extending parallel to an axis of light emission and connected to the concave portion at a discontinuity located farther from the substrate than a top of the at least one light-emitting element between the curved surface of the concave portion and the peripheral edge portion and thermally connected to the thermally conductive portion at a periphery of the light-emitting element by an adhesive; and a ridge portion formed on an exit side configured to project light emitted from the light-emitting element; the light distribution control member configured to control distribution of the light emitted from the light-emitting element; and 
 a cover thermally connected to the ridge portion and configured to pass therethrough the light emitted from the light-emitting element. 
 
     
     
       2. The light-emitting module according to  claim 1 , wherein
 the ridge portion is connected by an adhesive to the cover along an entire outer circumference of the light-emitting element. 
 
     
     
       3. The light-emitting module according to  claim 1 , wherein
 the thermally conductive portion also serves as the interconnect pattern, and the light-emitting element is electrically and thermally connected to the thermally conductive portion. 
 
     
     
       4. The light-emitting module according to  claim 1 , wherein
 the thermally conductive portion is formed on 70% or more of an area of the surface of the substrate. 
 
     
     
       5. The light-emitting module according to  claim 1 , further comprising:
 a first connecting portion serving as a heat entry portion provided between the light-emitting element and the thermally conductive portion; 
 a second connecting portion between the thermally conductive portion and the light distribution control member; 
 a third connecting portion between the ridge portion and the cover; and 
 a light exit surface serving as a thermally radiative portion provided on the cover, and wherein 
 the first connecting portion, the thermally conductive portion, the second connecting portion, the light distribution control member, the third connecting portion, and the cover are configured such that a temperature difference from the heat entry portion to the thermally radiative portion becomes no greater than 15 [K]. 
 
     
     
       6. The light-emitting module according to  claim 1 , wherein
 the at least one light-emitting element comprises a plurality of light-emitting elements; and 
 the at least one cup comprises a plurality of cups, one corresponding to each of the plurality of the light-emitting elements, respectively, each of the plurality of cups comprises four bended reflecting sections and boundary lines between the reflecting sections. 
 
     
     
       7. The light-emitting module according to  claim 6 , wherein
 each of the plurality of cups has a rectangular-shaped opening portion surrounded by the ridge portion; and 
 each ridge portion includes straight segments. 
 
     
     
       8. A luminaire comprising:
 a substrate including a thermally conductive portion and an interconnect pattern which are formed on a flat surface in the same plane; 
 at least one light-emitting element thermally connected to the thermally conductive portion by solder, electrically connected to the interconnect pattern, and configured to generate heat while emitting light; 
 a light distribution control member formed separately from the substrate, the light distribution control member comprising at least one cup corresponding to each of the at least one light-emitting elements, each of the at least one cup comprising a concave portion having a curved surface; a peripheral edge portion located on an incident side with respect to the at least one light-emitting element and extending parallel to an axis of light emission and connected to the concave portion at a discontinuity located farther from the substrate than a top of the at least one light-emitting element between the curved surface of the concave portion and the peripheral edge portion and thermally connected to the thermally conductive portion at a periphery of the light-emitting element by an adhesive; and a ridge portion formed on an exit side configured to project light emitted from the light-emitting element; the light distribution control member configured to control distribution of the light emitted from the light-emitting element; 
 a cover thermally connected to the ridge portion and configured to pass therethrough the light emitted from the light-emitting element; 
 a main body configured to hold at least the substrate; and 
 a lighting circuit connected to the interconnect pattern and configured to control lighting of the light-emitting element. 
 
     
     
       9. The luminaire according to  claim 8 , wherein
 power applied to the light-emitting element per unit area of an exit surface of the cover serving as a thermally radiative portion is no greater than 400 [W/m.sup.2]. 
 
     
     
       10. The light-emitting module according to  claim 8 , wherein
 the at least one light-emitting element comprises a plurality of light-emitting elements; and 
 the at least one cup comprises a plurality of cups, one corresponding to each of the plurality of the light-emitting elements, respectively, each of the plurality of cups comprises four bended reflecting sections and boundary lines between the reflecting sections. 
 
     
     
       11. The light-emitting module according to  claim 10 , wherein
 each of the plurality of cups has a rectangular-shaped opening portion surrounded by the ridge portion; and 
 each ridge portion includes straight segments. 
 
     
     
       12. A luminaire comprising:
 a main body including an attaching portion and a cavity; 
 at least one light-emitting module disposed in the cavity and fastened on the attaching portion, the light-emitting module comprising: a thermally conductive portion formed on an opposite side from the attaching portion; and at least one light-emitting element thermally connected to the thermally conductive portion by solder and configured to generate heat while emitting light; 
 a cover configured to cover the cavity, and to allow light emitted from the light-emitting element to pass through; and 
 a light distribution control member comprising at least one cup corresponding to each of the at least one light-emitting elements, each of the at least one cup comprising a concave portion having a curved surface; and a peripheral edge located on an incident side with respect to the at least one light-emitting element and extending parallel to an axis of light emission and connected to the concave portion at a discontinuity located farther from the substrate than a top of the at least one light-emitting element between the curved surface of the concave portion and the peripheral edge portion and thermally connected between the thermally conductive portion and the cover at a plurality of portions of the thermally conductive portion and a plurality of portions of the cover, and configured to transfer the heat generated by the light-emitting element to the cover directly for radiating the heat in a light-emitting direction. 
 
     
     
       13. The luminaire according to  claim 12 , wherein
 the luminaire comprises a plurality of light-emitting elements; 
 the light-emitting elements are arranged in a square matrix; and 
 the light distribution control member is configured to surround each light-emitting element and includes ridge portions disposed between the light-emitting elements, the ridge portions crossing each other. 
 
     
     
       14. The luminaire according to  claim 13 , wherein
 the ridge portions are thermally bonded to the cover by adhesive. 
 
     
     
       15. The light-emitting module according to  claim 12 , wherein
 the at least one light-emitting element comprises a plurality of light-emitting elements; and 
 the at least one cup comprises a plurality of cups, one corresponding to each of the plurality of the light-emitting elements, respectively, each of the plurality of cups comprises four bended reflecting sections and boundary lines between the reflecting sections. 
 
     
     
       16. The light-emitting module according to  claim 15 , wherein
 each of the plurality of cups has a rectangular-shaped opening portion surrounded by a ridge portion; and 
 each ridge portion includes straight segments.